Makita DCS460 Betriebsanleitung

REPAIR MANUAL

DCS460

DCS510

DCS5121

EA5000P53G

PS-460

PS-510

PS-5105

Page

Technical data ........................................................................................................................................................................... 3

Troubleshooting ........................................................................................................................................................................ 4

00 Special tools.......................................................................................................................................................................... 5 - 7

01 Sprocket guard / Chain tensioning system ................................................................................................................................ 8

02 Clutch drum / Rim sprocket ....................................................................................................................................................... 9

03 Chain brake / Guide bar bolt ............................................................................................................................................ 10 - 11

04 Clutch................................................................................................................................................................................ 12 - 13

05 Oil pump................................................................................................................................................................................... 14

06 Starter ...................................................................................................................................................................................... 15

07 Ignition system (trouble-shooting) ............................................................................................................................................ 16

07 Ignition system ................................................................................................................................................................. 17 – 18

08 Carburetor........................................................................................................................................................................ 19 – 20

09 Vibration damper...................................................................................................................................................................... 21

10 Tank................................................................................................................................................................................. 22 – 23

11 Cylinder / Piston .............................................................................................................................................................. 24 – 26

12 Crankcase / Crankshaft ........................................................................................................................................................... 27

13 Handle Heating ................................................................................................................................................................ 28 - 30

14 Torques ................................................................................................................................................................................... 31

CONTENTS

DCS460/

DCS461

DCS500

DCS501

DCS4600 DCS5000

DCS5001

DCS510

Stroke volume cm345.6 49.9 45.6 49.9 3.1 cu. in

Bore mm 43 45 43 45 1.77 inch

Stroke mm 31.4 1.24 inch

Max. power at speed 3) kW / 1/min 2.2 / 10,000 2.4 / 10,000 2.6 / 10,000 2.8 / 10,000 3.3 / 10,000

Max. torque at speed

Nm / 1/min 2.7 / 7,000 2.9 / 7,000 2.8 / 7,000 3.1 / 7,000 2.9 / 7,000

Idling speed / max. engine speed with bar and chain 1/min 2,500 / 13,500 2,500 / 14,500 2.500 / 13,500

Clutch engagement speed 1/min 3.900

Sound pressure level at the workplace L

pA av

per ISO/CD 22868

dB (A) 102.1 102.4 101.2 101 -

Sound power level LWA av per ISO/CD 22868 1) dB (A) 108.3 108.8 109.1 108.6 -

Sound Pressure Level at the operator‘s ear

at full load according to ANSI B 175.1 dB (A) - 103.9

Sound Pressure Level at the bystander‘s position

(50 ft/15 m distance) according to ANSI B 175.1 dB (A) - 76.2

Vibration acceleration ah,w eq per ISO 22867 1)

- Tubular handle m/s24.1 5.2 4.1 5.2 -

- Rear handle m/s23.6 3.7 3.6 3.7 -

Carburetor (diaphragm, choke flap carburetor) Typ membrane carburetor ZAMA membrane carburetor

Ignition system Typ condenser ignition system electronic condenser ignition system

Spark plug Typ NGK BPMR 7A

Electrode gap mm 0.5

or spark plug Typ BOSCH WSR 6F

Fuel consumption at max. load per ISO 7293 3) kg/h 1.1 1.2 1.3 1.2

Specific consumption at max. load per ISO 7293 3) g/kWh 500 450 480

Fuel tank capacity l 0.47 15.9 floz

Chain oil tank capacity l 0.27 9.1 floz

Mixture ratio (fuel/two-stroke oil)

- when using DOLMAR oil 50 : 1 / 100 : 1 (HP-100) 50 : 1 50 : 1 50 : 1 / 100 : 1 (HP-100)

- when using Aspen Alkalyt 50 : 1 (2%) - 50 : 1 (2%)

- when using other oils 40 : 1 (JASO FC or ISO EGD) 40 : 1 40 : 1 40 : 1 (JASO FC or ISO EGD)

Chain brake engages manually or in case of kickback

Chain speed 2) m/s 19.3 / 22.2 -

Sprocket pitch inch .325 oder 3/8

Number of teeth Z 7

Chain type see the Extract from the spare-parts list

Pitch / gauge inch .325 / 0.050, 0.058 oder 3/8 / 0.058 .325 / 0.050 oder 3/8 / 0.050

Guide bar, length of a cut cm 33 / 38 / 45 / 53 16 / 18 inch

Guide-bar type see the Extract from the spare-parts list

Weight (fuel tank empty, without chain, guide bar and accessories) kg 5.5 5.1 12.1 lbs

1) Figures derived in equal part from idling, full-load and racing speed.

2) At max. power

3) For models without starting valve

TECHNICAL DATA

___

Malfunction System Observation Cause

Chain does not run Chain brake Engine runs Chain brake actuated, Chain too tight

Engine does not start or

only with difficulty

Ignition system Ignition spark

No ignition spark

Malfunction in fuel supply system, pressure system,

mechanical malfunction.

Switch on STOP, fault or short-circuit in the wiring,

plug cap or spark plug defective,

gap between ignition module and flywheel uneven or too wide

Fuel supply

Compression

Mechanical malfunction

Fuel tank is filled

Inside system

Outside

Starter does not engage

Combination switch in Choke position,

carburetor defective, suction head dirty,

fuel line bent, leaky or interrupted.

Cylinder base packing ring defective, radial shaft packings defective,

cylinder or piston rings defective

Spark plug does not seal.

Spring in starter broken, broken parts inside the engine.

Engine speed gets “stuck” Multiple systems Engine speed about

4500 - 6000 rpm

Carburetor too lean

Bleed air at cylinder and/or rubber induction piece

Fuel line bent. Bowden cable sticking

Warm engine won’t start Carburetor Fuel tank is filled

Ignition spark

Wrong carburetor adjustment

Flooded from choke use

Engine starts, but

dies immediately

Fuel supply Fuel tank is filled Wrong idling adjustment, suction head or carburetor dirty,

tank venting defective, fuel line interrupted, cable defective,

Choke flap closed, decompression valve dirty

Insufficient power Several systems

may be involved

simultaneously

Engine is idling Air filter dirty, wrong carburetor adjustment, muffler clogged,

exhaust channel in cylinder clogged, spark arrester screen clogged.

No chain lubrication Oil tank/pump No oil on the chain Oil tank empty

Oil guide groove dirty, Oil suction head dirty

Oil pump adjusting screw incorrectly adjusted

Oil pump worm drive gear defective

TROUBLESHOOTING

12 3

SPECIAL TOOLS

1 Torx screwdriver

Grip (944.500.860)

T-grip 200 mm (944.500.862)

T-grip 100 mm (944.500.861)

2 Radial ring puller

13 mm radial ring puller (944.500.871)

Spindle (950.203.020)

3 Mandrel

Disassembly mandrel for

tapping out the flywheel

without damage to

the crankshaft thread (944.500.880)

4 Setting gauge

Gauge for measuring the gap

between flywheel and

armature (944.500.891)

5 Torque wrench

3/8” Drive socket (944.500.864)

Bit, 152 mm (944.500.865)

Bit, 49 mm (944.500.866)

Torque wrench

3/8” Drive (950.230.000)

6 Piston stop wedge

Wedge for blocking

the engine through the

exhaust port (944.602.000)

7 8

12 13 14

SPECIAL TOOLS

7 Piston ring tensioner

Piston ring band and

assembly tool for cylinders (944.600.001)

8 Assembly and disassembly wrench

Wrench for disassembling and

assembling the centrifugal

clutch (944.500.590)

9 Pressure gauge

Pressure gauge for checking

the carburetor fuel valve (956.004.000)

10 Tachometer

Electronic tachometer for measuring

the engine speed of

2- and 4-stroke engines (950.233.220)

11 3/8” socket

Installation/removal of

Spark plug, clutch (944.500.864)

12 Needle-nose pliers

Various assembly/

disassembly tasks (944.603.400)

13 Disassembly hook

Removal/installation

Brake band spring (950.237.000)

14 Over/underpressure pump

For checking sealing of

radial rings and gaskets

15 16

SPECIAL TOOLS

15 Sealing plate

For sealing intake side (944.603.170)

16 Sealing plate

For sealing exhaust side (944.603.170)

SPROCKET GUARD / CHAIN TENSIONING SYSTEM

Chip deflector in the sprocket guard

CAUTION: To prevent cuts, wear protective

gloves!

Remove the sprocket guard, bar, and chain.

Use the combination wrench to disengage the

chip deflector, and remove it.

Note for changing the type of chain: If using

a 3/8" saw chain, be sure to first cut out the

the marked portion of the chip deflector 1!

Before converting to a.325” chain it will be

necessary to install a new chip deflector

(957.213.220).

CAUTION: Before removing the cover

plate, first set off the chain brake!

Chain tensioner

Unscrew 3 bolts and remove the cover.

Chain tensioner function

An angled worm drive converts the turns of

the adjustment screw to forward or backward

motion of the tensioning pin.

Grease the spindle and worm gear with multi-

purpose grease (944.360.000).

Unscrew screw and pull chain tensioner up

and out.

Assembly

CLUTCH DRUM / RIM SPROCKET

Remove the sprocket guard, bar, and chain.

Remove the circlip 5with the universal

wrench.

Pull the handguard towards the front handle to

release the chain brake if necessary.

Chain sprocket and clutch drum with

needle bearing

Check the chain sprocket 4for damage and

wear.

Important customer information:

Before installing a new saw chain, always

check the condition of the chain sprocket. A

worn chain sprocket will damage a new saw

chain, and must be replaced.

Check the clutch drum needle bearing for

wear and damage.

Assemble

the bearing with multi-purpose high-

performance grease (944.360.000).

Check the inside of the clutch drum 3for

damage and wear.

Replace the clutch drum if damaged or worn.

Important: Always replace the washer disc

Note: Always use a new circlip 5

(927.408.000)!

When assembling the clutch drum, make

sure that the lug of the clutch drum 2 is not

positioned on the oil pump drive. When

inserting, turn the clutch drum slightly.

Secure the chain saw from slipping (vise).

Using the disassembly hook (Chap. 00, Pos.

14), disengage the brake band spring 3.

Remove the handguard and

disengagement mechanism

Remove the hood.

Unscrew bolt 4and pull out the sleeve 5.

Remove the black spacer 6.

4 5

1 2

CHAIN BR

AKE / GUIDE BAR BOLT

Removing the brake band

CAUTION: To prevent cuts, wear protective

gloves and remove the spike bar (2 bolts)!

Remove the sprocket guard, bar, and chain.

Pull the handguard towards the front handle to

release the chain brake.

Remove the clutch drum, see Chapter 02.

Push the hand guard forward to engage the

chain brake. This tensions the brake band

spring.

Remove the cover plate, see Chapter 01.

Fold the brake band 1upward and turn it out

of the disengagement mechanism 2.

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